Ductless electrical floor covering conducting system,and components therefor

ABSTRACT

A ductless electrical conducting system comprises a flexible strip structure forming part of floor covering on a floor foundation, and having laterally spaced conductors and a protective ground strip thereover, all insulated from each other. Access openings in the top of the strip structure for electrical connectors and for fastening screws to attach a connector device, are provided with removable plugs when connection is required. Sets of such access openings at predetermined locations along the strip structure enable selection of locations for electrical connection.

United States Patent William B. Tenery 36053 Haley St., Newark, Calif. 94560 839,385

July 7, 1969 Sept. 28, 1971 Inventor Appl. No. Filed Patented DUCTLESS ELECTRICAL FLOOR COVERING CONDUCTING SYSTEM, AND COMPONENTS THEREFOR 11 Claims, 19 Drawing Figs.

US. Cl 339/14 R,

339/22 R Int. Cl H0ir 3/06 Field of Search 339/14, 22,

96,21-24; l74/ll7.l, 117.11

a Z///// k [56] References Cited UNITED STATES PATENTS 2,666,907 1/1954 Hensley 339/22 R 3,459,879 8/1969 Gerpheide 174/1 17 (.1 1)

Primary ExaminerMarvin A. Champion Assistant Examiner Robert A. Hafer Attorney-Stanley Bialos PATENT EU SEP28 I97! w :1 FL

PATENT-EDSEP28I97I 3,609,629

SHEET 3 UF 4 /n vencorr William B. Tens/y By Attorney PATENTEU SEPE' 82971 SHEET 0F 4 FIG.|7

FIG-J6 Attorney Inventor: William B. Tene DUCTLESS ELECTRICAL FLOOR COVERING CONDUCTING SYSTEM, AND COMPONENTS THEREFOR BACKGROUND OF THE INVENTION Electrical conducting systems now generally employed for floor distribution in modern buildings generally comprise flat ducts which are laid on a floor foundation to form a grid. The remainder of the floor is then brought to level with a fill, usually concrete, and finished with floor covering. Wires are pulled through selected ducts to the desired location of outlets. Such type of system is relatively expensive, and requires substantial installation time.

SUMMARY AND OBJECTS Summarizing the invention hereof, it eliminates the necessity of ducts, and comprises a flexible strip structure of substantially the same thickness as standard floor covering materials, such as vinyl tile. It may be installed on new floor foundations to form part of the floor covering. On existing floors having floor covering already laid thereon, strips of such covering may be removed, and the strip structure hereof may be laid and secured in the spaces from which the floor covering is removed to thus form part of the floor covering. A plurality of such strips may be laid at suitable locations on the floor foundation.

Desirably the strip structure is a unitary strip although a plurality of strips may be laid side by side. The flexibility of the strip enables it to be removed from a coil or roll thereof, and to bc easily and smoothly laid.

Each strip is relatively thin and is provided with laterally spaced apart conductors. The conductors are protected by an overlying ground strip; and the insulation is provided about the conductors and about the ground strip. Preformed holes in the top of the strip are sealed with removably mounted plugs which provide access openings for connection of electrical connectors at a suitable modular location along the strip and for fastening means to attach a connection device carrying the electrical connectors. A feed-in device adjacent an end of the strip provides for connection to electrical circuits and for a grounding connection.

The strip is desirably provided with sets of such access openings at suitable locations along its length to enable selection of a desired location for electrical connection. In this connection, a plurality of such strips may be laid on the floor foundation. The upper exposed surfaces of such strip and the plugs are desirably finished in a color or pattern which are acceptable or compatible with a variety of floors, so that the appearance of the entire floor covering is not impaired.

From the preceding it is seen that the invention has as its objects, among others, the provision of an improved ductless electrical conducting system of economical and simple construction which forms part of thefloor covering on a floor foundation thus obviating the necessity of having to provide ducts and pulling wires therethrough, which is safe to employ, and includes a flexible strip structure which may be laid on the floor foundation in a simple manner and provide a pleasing appearance, and the provision of quickly attachable electrical connection means for such system. Other objects of the invention will become apparent from the following more detailed description and accompanying drawings in which:

DESCRIPTION OF DRAWINGS FIG. 1 is a more or less schematic isometric view of a section of floor having the system hereof on a floor foundation, and illustrating in phantom lines a connection device for such system;

FIG. 2 is a plan view substantially to full scale, of a portion of the strip structure hereof;

FIG. 3 is a plan view similar to FIG. 2 but illustrating a connection device in position;

FIG. 4 is an enlarged longitudinal cross-sectional view taken in planes indicated by line 44 in FIG. 2; the longitudinal dimension being substantially full scale, and the vertical dimension being ten times the scale of the longitudinal dimension to illustrate the construction more clearly;

FIG. 5 is a similarly enlarged longitudinal section taken in planes indicated by line 5-5 in FIG. 3 with the upper half of the connection device broken away;

FIG. 6 is an enlarged transverse section taken in planes indicated by line 6-6 in FIG. 2, the vertical dimension also being ten times the scale of the transverse dimension;

FIG. 7 is an enlarged transverse section taken in planes indicated by line 7-7 in FIG. 3 and line 7-7 in FIG. I, with the upper portion of the connection device broken away, and illustrating the floor foundation and floor covering against the strip structure;

FIG. 8 is a vertically enlarged transverse section taken in a plane indicated by line 8-8 in FIG. 2;

FIG. 9 is a plan view of the connection device;

FIG. 10 is a longitudinal section taken in planes indicated by line 10-10 in FIG. 9;

FIG. 11 is an isometric view of one of a pair of connector elements embedded in the connection device of FIGS. 9 and 10;

FIG. 12 is an enlarged elevational view of a desirable form of screw for effecting locking attachment of the connection device to the strip;

FIG. 13 is a fragmentary isometric view of a type of locking flange provided on a ground strip in the strip structure for effecting locking of the screw of FIG. 12;

FIG. 14 is a front elevational view with a portion of the cover broken away, of a form of feed-in box that may be employed for connection to the strip conductors and ground strip;

FIG. 15 is a vertical transverse section through the feed-in box taken in planes indicated by line 15-15 in FIG. 14;

FIG. 16 is a fragmentary elevational view illustrating offsetting and sealing of the circuit conductors from the ground strip at a cut end of the strip structure thereof;

FIG. 17 is a similar view for feedin box termination;

FIG. 18 is a transverse sectional view of a form of strip structure hereof for telephone use; and

FIG. 19 is a transverse section illustrating a manner of laying the strip structure for carpet floor covering.

DETAILED DESCRIPTION With reference to FIG. 1, conventional floor covering 2 which may be linoleum or suitable tile, such as vinyl tile, is supported on the usual floor foundation 3 such as wood or cement. If the installation is initially laid on the floor, parallel spaced apart gaps are provided in covering 2 to receive electrical connection strip structures 4 which will be described in detail hereinafter. Although one strip 4 may be employed, any number of strips may be provided to fonn part of the floor covering 2. For purposes of illustration two such strips 4 are shown in FIG. 1.

The strips are of a thickness substantially equal to that of floor covering 2 so as to present ah upper surface substantially even and compatible therewith, and thus form part of covering 2. The color of the upper surface of the strips is desirably such as to blend in or be substantially the same as the floor covering to create a neat appearance. At an end thereof each strip 4 is connected to a feed-in box 5 adjacent a wall 6 in a manner to be described.

At suitable predetermined locations indicated by A, B, C and D shown in FIG. 1, the strips are provided with openings 7 which are normally sealed by removably mounted plugs, to receive electrical connectors when the plugs are removed; the connectors being provided on a connection device 8 shown in phantom lines at position B. Additional plugged openings 9 are provided at each location for the securing of a connection device when so desired. As a result of the described arrangement, connecting stations are provided at suitable intervals to which electrical connections may be made in accordance with requirements of the occupant of the premises.

Strip 4 is flexible so that it may be readily handles, and unwound from a coil or roll thereof when being laid on foundation 3. Desirably, it is relatively narrow and thin. A suitable width is about 2 inches, although this width is not particularly critical, and a suitable thickness is about 0. I25 inch which is substantially the thickness of conventional hard surface floor covering such as floor tile or linoleum.

As can be seen best from FIGS. 2 and 4, each strip 4 includes a pair of spaced apart metal conductors 11 and 12 one of which in a single phase circuit, is a hot conductor and the other of which is neutral. Each conductor strip 11 and 12 consists of a pair of metal conducting strips 13 in free unattached engagement. Overlying conductors 11 and 12 and spaced therefrom is a protective metal ground armor in the form of a strip 14 extending longitudinally the entire length of conducting strip 4, and which extends laterally beyond connectors 11 and 12 to protect them completely. Conducting strips 11 and 12 and ground armor 14 are all insulated from each other by insulation about conductors 11 and 12 and about ground annor 14.

By way of example, each metal conducting strip 13 is desirably of copper or aluminum about 0.020 inch thick; and ground armor strip 14 is of stronger metal, such as steel, to provide a protective shield against penetration by tacks or the like, and about 0.020 inch thick; the layer of insulation in the space between conductors 11 and 12 and ground strip 14 being about 0.020 inch. The under layer of insulation of strip 4 below conductors 11 and 12 is about .020 inch thick, and the thickness of the upper layer of insulation above ground strip 14 about 0.025 inch.

Any suitable manner may be employed for forming strip 4 but it is advantageous for purposes of assembly to form it in separate sections all integrally laminated together. As can be seen best from FIGS. 6 and 8, each lower conducting strip 13 is embedded in the upper surface of a suitable plastic strip 16, desirably of Nylon or Teflon; and such strip 16 is bonded either by heat sealing or suitable adhesive to a similar intermediate plastic strip 17 which has embedded in the underside thereof upper conducting strips 13.

Each of the upper conducting strips 13 is preformed with a hole 18; and intermediate plastic strip 17 is preformed with a matching hole 19. Protective ground armor strip 14 is adhesively bonded to and embedded in the underside of a top plastic cover strip 21, and is also adhesively bonded to intermediate plastic strip 17. Top cover strip 21 is desirably of vinyl to match vinyl tile commonly employed as floor covering, and is bonded at its margins to intermediate strip 17. Thus, the entire strip structure 4 is formed as a unitary mass in which conductors l1 and 12, and ground strip 14 are all insulated with respect to each other, and the top and bottom are layers of insulation.

Above matching holes 18 and 19, a removable plug 22 is punched out of armor 14, and a similar removable matching plug 23 is punched out of top floor covering strip 21. These plugs 22 and 23 match holes 18 and 19, and form the aforementioned plugged and sealed access opening 7. They remain in place when strip 4 is laid on foundation 3, but when a connection is to be made can be readily removed by a suitable instrument, such as a pick, to uncover the entire access opening 7 which extends through the top of strip 4 and through lower conducting strip 13 to the freely separable interface between upper and lower conducting strips 13.

Means is provided for enabling secure connection of a connection device 8 to a selected location at which an electrical connection is made. For this purpose as can be seen best from FIGS. 4 and 5, intermediate plastic insulating strip 17 is provided with a pair of longitudinally spaced apart preformed holes 24; and in alignment with these respective holes 24, armor ground strip 14 and top strip 21 are formed with matching removable plugs 25 and 26, respectively, which when removed enable attachment of a connection device 8. As can be seen from FIGS. and 7 which illustrate the lower portion of an attached junction device 8, and from FIGS. 9 through 13, the device includes a pair of metal connector elements 27 each of which has an outwardly projecting finger 28 which when the connection device is mounted on a strip 4 as shown in FIG. 6 can be readily engaged between unattached conductor strips 13 of a conductor 11 or 12 to make electrical contact.

In this connection, it will be noted that in the formation of each preformed hole 18 in an upper conducting strip 13, a slight chamfer is provided in the lower surface of the strip about such hole. This facilitates insertion of a finger 28 between a pair of conducting strips 13. The underside of connection device 8 is provided with a plug 29 which plugs and seals the electrical connection access opening 7 after plugs 22 and 23 are removed and connection device 8 is attached.

As can be seen from FIG. 5, the connection device 8 is securely attached in fixed position by means of a pair of screws 31, each having a lower helical thread 32, and which is insertable through a hole 33 in the connection device, and through an access opening 9 after plugs 25 and 26 are removed therefrom. Helical threads are such length as to engage and lock against the underside of ground strip guard 14, which is formed with a lock flange 34 as can be seen from FIG. 13.

The body of connection device 8 is formed of any suitable moldable plastic or other insulating material which is molded about a pair of contact members 37 on which connector elements 27 are integrally formed. Each member 37 comprises an integral stamping of copper or aluminum which is folded over along a fold line 38, and formed with a corner recess 39 from which material for downwardly extending connector elements 27 are provided.

Adjacent the ends along one side thereof, each member 37 is formed with upstanding spaced apart prongs 41 which provide contact elements for connection of jack plugs in the space 42 between each pair of such prongs. It will be noted that each sealing plug 29 of the connection device is integrally molded about a connector element 27; and the bottom of the connection device body is formed with a marginal flange 43 which insures sealing of the device against floor strip structure 4 and the floor covering adjacent thereto, when it is attached by fastening screws 31. Thus a watertight construction is provided.

A ground armor sheet 46 is embedded in the body of connection device 8 and overlies connector elements 27 to protect the same; the sheet 46 being provided with an aperture 46 about each pair of prongs 41, and also being provided with a pair of apertures 47 each having a contact 48 secured to ground sheet 46 to receive a conventional pair of jack plugs for grounding. Ground sheet 46 as well as ground armor 14 in the strip 4 serve the important purpose of preventing accidental shock should tacks or nails penetrate these structures, and which might also occur by exposure of the circuit conductors due to abrasion and wear.

From the preceding, it is seen that since all access openings are plugged, the top surface of the strip 4 is watertight. When a connection device 8 is to be attached at a desired location, the plugs, particularly the larger plugs 23 in top cover 21, serve as a means to identify such location because the interface between the plugs and cover strip 21 can be observed by relatively close inspection although they are otherwise substantially invisible because they are designed to blend in or be compatible in color and design with strip 21.

After removal of the plugs, a connection device 8 can be readily attached in the manner previously explained. In this connection, it will be noted, particularly from FIGS. 2 and 3, that the plugged connection access openings 7 for receiving connector elements 27 are longitudinally offset relative to each other to insure that in the single phase circuit illustrated, proper connectionin made when a connection device 8 is attached at a selected location on strip 4.

Any suitable type of feed-in box 5 positioned adjacent an end of strip 4 may be employed in which the conductors and ground strip are connected. A desirable form of such feed-in box, illustrated in FIGS. 14 and 15, comprises a hollow metal receptacle having a removably secured front cover of insulating material, such as plastic, and knockouts 52 for entrance of circuitry conduits. A portion of the ground strip 14 and upper layer 21 is cutoff at an end of strip 4, as is indicated at 53 in FIG. 15.

The strip at such cutoff portion is bent upwardly against a mounting base 54 of insulating material, and clamped thereto by means of a clamping plate 56 and a clamping screw 57 secured in base 54. The lower end of clamping plate 56 is recessed to receive a grounding wire 58 which is connected to ground strip 14 by a screw 59 secured in base 54.

Thus, a grounding connection is provided between grounding wire 58 and ground strip 14. Circuitry connections are provided between the respective conducting strips 13 of conductors 11 and 12. For this purpose, a wedge shaped contact 61 is inserted between the top ends of each pair of conducting strips 13 in a conductor 11 or 12. Such contact is connected to a lead-in wire 62 by a screw 63 extending through an insulating plate 64 and clamping the wire to contact 61 by means of insulating clamp plate 65 in which screw 63 is fastened.

Installation conditions generally require cutting strip 4 either in the feed-in box or at a floor location. Where this is done, the ends of the ground armor strip 14 and the circuit conductors 11 and 12 formed by the respective pairs of strips 13 are desirably offset by cutting, to provide adequate creep distance between the hot and grounded conductors, and are sealed with insulation 66, such as a pressure sensitive adhesive. FIG. 16 illustrates the offset relationship between strips 13 and the ground strip 14 for termination at a floor location, while FIG. 17 illustrates termination at feed-in box 5.

FIG. 18 illustrates a convenient strip structure for adaptation with conventional telephone connectors. Strip 74 of substantially the same construction previously described, has an upper protective ground strip 76 and spaced apart conductors 77 insulated from each other and from ground strip 76, each being composed of a pair of freely engaged conductor strips 78 between which suitable connector elements are insertable in the manner described.

when strip 4 is laid on a floor foundation to which hard top floor covering, such as vinyl tile, is secured, the tile and the strip rest directly on the foundation so that the floor surface of the strip presents an even surface with the floor covering tile, being of substantially the same thickness. When employed in association with carpeting, the same principle applies because as illustrated in FIG. 19, carpeting is usually laid over floor covering padding 79 directly on the foundation. The aforementioned strip 4 of substantially the same thickness as padding 79 to provide an upper surface even with the upper surface of the padding, is laid adjacent thereto; and carpeting 81 is next laid over the padding and the strip without any bulges.

Although strip 4 is not exposed in the arrangement of FIG. 19, location of strips may be determined by any suitable means of identification. For example, the baseboard of the room in which the carpeting is laid may be marked inconspicuously to indicate the location of a strip 4; and since the connection locations for a connection device 8 are desirably spaced apart at equal intervals, the particular location at which a connection is to be made may be readily ascertained. In making a connection, a small piece of the carpet equal in width of strip 4, and slightly less in length, is removed, and the device attached. The width of the device is slightly greater than that of strip 4, as can be seen from FIG. 4. This enables the tight seal previously described.

lclaim:

l. A ductless electrical conducting system on a floor foundation having a floor covering thereover comprising a flat floor strip structure supported by said foundation and forming part of said floor covering; the strip structure having laterally spaced apart conductors each of which comprises a pair of relatively thin flexible metal conducting strips extending substantially longitudinally thereof, said strips of each conductor being in free contact with each other to receive an electrical connector insertable therebetween, an overlying protective metal ground strip spaced above and covering said conductors, insulation about said conductors and about said protective ground strip, access openings in the top of said floor strip structure for receiving such electrical connectors, and plugs removably mounted in said access openings.

2. The system of claim 1 wherein said floor strip structure is of substantially the same thickness as said floor covering, and the conducting strips of each conductor are horizontally positioned to provide an upper strip and a lower strip, and each access opening extends through the upper strip.

3. The electrical conducting system of claim 1 having additional access openings in the top thereof for receiving fastening means for a connection device, and plugs removably mounted in said additional access openings.

4. The electrical conducting system of claim 3 with all the plugs removed in combination with a connection device attached to said floor strip structure and having bosses through which electrical connectors extend, said bosses plugging said electrical connector openings, the lower end portion of each of said electrical connectors being positioned between a pair of said conducting strips, and fastening means extending through said additional openings for securing said connection device to said floor strip structure.

5. The electrical conducting system of claim 3 wherein the upper surfaces of said floor strip structure and said plugs are compatible in color with the adjacent floor covering.

6. The electrical conducting system of claim 3 wherein said floor strip structure is provided with longitudinally spaced apart sets of plugged access openings at predetermined locations to enable selection of locations for electrical connections.

7. The electrical conducting system of claim 1 wherein a feed-in box is positioned adjacent an end of said floor strip structure, and said overlying protective ground strip is connected to ground in said feed-in box, and said spaced apart conductors are connected in said feed-in box to circuit conductors.

8. The electrical conducting system of claim 1 comprising a plurality of said floor strip structures supported by said foundation at predetermined locations with said floor covering between adjacent strip structures.

9. A flexible floor covering strip structure for support on a floor foundation adjacent floor covering and having means for conducting electrical current and means for attachment of an electrical connection device thereto to provide a ductless electrical conducting system, comprising laterally spaced apart conductors extending substantially longitudinally thereof, an overlying protective metal ground strip spaced above and covering said conductors, insulation about said conductors and about said ground strip, access openings in the top of said floor strip structure including the ground strip for receiving electrical connections, and sealing plugs removably mounted in said access openings.

10. A ductless electrical conducting system on a floor foundation having floor covering thereover, comprising a floor strip structure supported by said foundation and forming part of said floor covering; the strip structure having laterally spaced apart conductors extending substantially longitudinally thereof, an overlying protective metal ground strip spaced above and covering said conductors; insulation about said conductors and about said protective ground strip, access openings in the top of said floor strip structure including said ground strip for receiving electrical connectors, and sealing ground strip spaced above said conductors, insulation about said conductors and about said ground strip, access openings in the top of said floor strip structure for receiving electrical connections, and sealing plugs removably mounted in said access openings, each of said conductors comprising a pair of relatively thin flexible conducting strips in free contact with 

1. A ductless electrical conducting system on a floor foundation having a floor covering thereover comprising a flat floor strip structure supported by said foundation and forming part of said floor covering; the strip structure having laterally spaced apart conductors each of which comprises a pair of relatively thin flexible metal conducting strips extending substantially longitudinally thereof, said strips of each conductor being in free contact with each other to receive an electrical connector insertable therebetween, an overlying protective metal ground strip spaced above and covering said conductors, insulation about said conductors and about said protective ground strip, access openings in the top of said floor strip structure for receiving such electrical connectors, and plugs removably mounted in said access openings.
 2. The system of claim 1 wherein said floor strip structure is of substantially the same thickness as said floor covering, and the conducting strips of each conductor are horizontally positioned to provide an upper strip and a lower strip, and each access opening extends through the upper strip.
 3. The electrical conducting system of claim 1 having additional access openings in the top thereof for receiving fastening means for a connection device, and plugs removably mounted in said additional access openings.
 4. The electrical conducting system of claim 3 with all the plugs removed in combination with a connection device attached to said floor strip structure and having bosses through which electrical connectors extend, said bosses plugging said electrical connector openings, the lower end portion of each of said electrical connectors being positioned between a pair of said conducting strips, and fastening means extending through said additional openings for securing said connection device to said floor strip structure.
 5. The electrical conducting system of claim 3 wherein the upper surfaces of said floor strip structure and said plugs are compatible in color with the adjacent floor covering.
 6. The electrical conducting system of claim 3 wherein said floor strip structure is provided with longitudinally spaced apart sets of plugged access openings at predetermined locations to enable selection of locations for electrical connections.
 7. The electrical conducting system of claim 1 wherein a feed-in box is positioned adjacent an end of said floor strip structure, and said overlying protective ground strip is connected to ground in said feed-in box, and said spaced apart conductors are connected in said feed-in box to circuit conductors.
 8. The electrical conducting system of claim 1 comprising a plurality of said floor strip structures supported by said foundation at predetermined locations with said floor covering between adjacent strip structures.
 9. A flexible floor covering strip structure for support on a floor foundation Adjacent floor covering and having means for conducting electrical current and means for attachment of an electrical connection device thereto to provide a ductless electrical conducting system, comprising laterally spaced apart conductors extending substantially longitudinally thereof, an overlying protective metal ground strip spaced above and covering said conductors, insulation about said conductors and about said ground strip, access openings in the top of said floor strip structure including the ground strip for receiving electrical connections, and sealing plugs removably mounted in said access openings.
 10. A ductless electrical conducting system on a floor foundation having floor covering thereover, comprising a floor strip structure supported by said foundation and forming part of said floor covering; the strip structure having laterally spaced apart conductors extending substantially longitudinally thereof, an overlying protective metal ground strip spaced above and covering said conductors; insulation about said conductors and about said protective ground strip, access openings in the top of said floor strip structure including said ground strip for receiving electrical connectors, and sealing plugs removably mounted in said access openings.
 11. A flexible floor covering strip structure for support on a floor foundation adjacent floor covering and having means for conducting electrical current and means for attachment of an electrical connection device thereto to provide a ductless electrical conducting system, said strip structure being flat and of substantially the same thickness as the floor covering, and comprising laterally spaced apart conductors extending substantially longitudinally thereof, an overlying protective metal ground strip spaced above said conductors, insulation about said conductors and about said ground strip, access openings in the top of said floor strip structure for receiving electrical connections, and sealing plugs removably mounted in said access openings, each of said conductors comprising a pair of relatively thin flexible conducting strips in free contact with each other to receive an electrical connector insertable therebetween, said floor strip structure having additional access openings in the top thereof for receiving fastening means for attachment of said connection device, and sealing plugs removably mounted in said additional access openings. 